Prep for paint

Today's post will be the first post EVER without any pictures!! How boring I know!

With a surprise mention of someone going to the powdercoaters the boys took the opportunity to get it there. So all was stripped, metal was prepped (weld filled, sanded etc.) and all was boxed and labelled. 

(Insert pictures of a frame and parts)

Other parts Mackenzie took home to sand clean and lacquer bare metal parts.

The logbook was also altered and sent off to the dreaded DVLA. All included correct vin and engine numbers and paper work so all should be fine. Fingers crossed anyway!!! 

Brake master mounted

Today was the final day to mount things and what not before dissembling the bike for powder coating prep (clean all welds etc.). 

It was a bit tricky but the boys came up with a solution. As always! It was to be mounted on the down tube with a clever little cable guide modified from a few different cable and lever parts. 

The brake reservoir will simply bolt into the same fixing as the tank fixing.

A little bit of final welding here and there before the we can strip the frame and final weld the tricky underneath bits. 

Next up, disassemble the whole thing and organise paint, seat makers and wiring! 

Last bit of metal fab

The first small electric housing box made up was discussed and then decided it was to go. Although it was a decent size, the ignition switch was to be housed there and it simply wouldn't fit. 

With a bit of heat it sure did come out!

 

Once the box was out, a quick clean up of the frame rails and some new metal was required. 

A simple net shape was for the new bigger box. Then small slits were cut into the ridges for it all to be bent over and welded into a box!

Next up, that pesky remote master cylinder and it's reservoir is to be mounted!

Exhaust fab!

So today the boys fabbed the exhaust. With a set of pre bent bends bought, they set off to work. 

A cut down baffle was welded in to the original header to the joint that Haynes & Scott made. 

As a high level exhaust was wanted, a lot of ideas were thrown about. Then both decided it would look sweet coming through the mudguard. Yes through it! So a section was cut out to clear room for the pipe. Another baffle was also put in between bends. 

So here she is all her formed glory! A neat little bend down of the last section of pipe was kept too. 

Next up, odds and sods!

Seat pan completion!

So today the seat pan was completed. With the awkward high top mount of the shock, it protruded through the pan so a box was made to cover for easier foam laying. 

Next was to cut it out of metal. The transition from cardboard, to wood, to metal. 

It was was cut out, trimmed and mounted using the rear mudguard brace a front brace. Bolts were welded to the pan so a simple tightening of a bolt is all that is needed. 

The bike has now been moved back to Luke's workplace as it is nearly ready for paint!

A small box for the remaining wires and electrical components (regulator, CDI, relays etc.) was also fabricated. 

Next up, the exhaust!!

Seat Pan Prep

A very rough cardboard pan was cut out just to give a gauge for visual representation. Then used was the back of a late dissembled cabinet, this was perfect seat pan mock up material. 

A lot of ideas were throw around and due to the awkward high mounted top shock mount they were all needed!

In the end it was decided to cut a slot out for the mount do the pan could sit flush on the frame rails. To complete the pan a box will cover the mount. 

Mackenzie in full seat pan thought mode. 

Next up, seat pan measurement fine tuning and sheet metal cutting! 

Mudguard Done

The rear mudguard got the CC treatment this week, a narrowing, a welding up and a fitting. 

Also made was a shock protecter. This was done by removing a length of the edges at the bottom then cutting a small recess across the width so the "flap" can be pushed back to clear the bottom shock mount. It was then welded for strength and gave a quick clean up. 

It will up be cleaned up and sanded down at a later date. 

Next up, the seat pan!